INSTRUCTIONS

-J03483 1 of 7

General

This kit ts 2000 and later Softail and 2001 and later Touring
model motorcycles. Requires separate purchase of Cable
Sidecover Release Kit or Hydraulic Sidecover Release kit.
See retail catalog for part numbers.
In addition to the above kits, the 2005 Touring Model Service
Manual (Part Number 99483-05) and Main Drive Gear
Remover & Installer Kit (Part Number 35316-B) must be pur-
chased. See your Harley-Davidson dealer.
For a list of items contained in this kit, see the Service Parts
illustration.
1WARNING 1WARNING

The rider's safety depends upon the correct installation
of this kit. If the procedure is not within your capabilities
or you do not have the correct tools, have your Harley-
Davidson dealer perform the installation. Improper instal-
lation of this kit could result in death or serious injury.
(00308a)

NOTE
A Service Manual for your model motorcycle is available at
any Harley-Davidson Dealer.

Removal

NOTE
Leave the transmission case in the frame unless the case
itself requires replacement. For ease of illustration, photo-
graphs show the case removed.

1. Using the appropriate service manual, proceed as fol-
lows:
a. Drain the primary chaincase and transmission lubri-
cants.
1WARNING 1WARNING

To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
battery cable before proceeding. (00048a)

b. Unthread bolt and remove battery negative cable
(black) from battery negative (-) terminal.
c. Remove seat.
d. Remove the primary chaincase cover. Remove the
clutch assembly, primary chain, and compensating
sprocket components. Remove the starter jackshaft
assembly.
e. Remove the exhaust system as necessary to gain
complete access to the transmission side door.
f. Remove the oil ller spout and starter.
g. Remove the primary chaincase.
h. Remove the clutch release cover. Remove the clutch
cable from the clutch release cover.
i. Remove the vehicle speed sensor.
j. Remove the transmission top cover.
k. Remove the drum support blocks and shift drum.
Remove the drum support block dowels from deck
of transmission case.
l. Remove the fork shaft and shifter fork assemblies.
m. Remove the bearing inner race from the transmis-
sion mainshaft.
n. Remove the transmission side door and the main-
shaft/countershaft assembly.

NOTE
The front dowel pin may be stuck in the side door after
removal. If this occurs, remove the dowel pin from the side
door and install it back into the transmission case.

o. Remove the shifter shaft assembly and shifter seal.
p. Remove the main drive gear and bearing.

GEAR STOCK 5-SPEED SE 6-SPEED

First 3.210 3.210
Second 2.209 2.209
Third 1.572 1.572
Fourth 1.226 1.226
Fifth 1.000 1.000
Sixth N/A 0.885

Figure 1. Install Drill Plate to Transmission Case
9449

-J03483
REV. 02-11-2005

Kit Number 33102-03A

6 SPEED TRANSMISSION SUPER KIT

-J03483 2 of 7

NOTE
Detailed instructions on removing the main drive gear and
bearing can be found in the 2005 Touring Model Service Man-
ual (Part No. 99483-05),

Section 7.7 MAIN DRIVE GEAR/
BEARING.

q. Remove the countershaft needle bearing.
2. Using masking tape, cover all the side door ange holes
in the transmission case with the exception of the top
three.

NOTE
While the two threaded holes at the top of the ange are used
for mounting of the drill plate, the fork shaft hole (center thru
hole) is used as the pilot for the drill bits.

3. From inside the transmission case, tape over all bores as
follows:
Vehicle speed sensor and mounting screw bores
Transmission top cover and shift drum support block
screw bores
Transmission drain hole bore
Main drive gear bearing bore
Countershaft needle bearing bore
Fork shaft bore
Shifter shaft bore
CAUTION

Be sure drill plate is properly oriented. Improper orienta-
tion will result in damage that requires replacement of
the transmission case.

4. Obtain the drill plate (Part No. 35155-03) provided in kit
and fasten to top of side door ange using old and new
vehicle speed sensor mounting screws.
5. Spread one or two clean shop cloths inside the transmis-
sion case to catch the metal shavings and debris.
6. Starting with a 3/8 inch drill bit, alternately use progres-
sively larger bits to enlarge the fork shaft hole. Finish the
drilling operation with a 3/4 inch drill bit.
7. Remove all remaining material up to the edge of the drill
plate with a die grinder or similar tool. Remove the drill
plate.
8. Using emery cloth, steel wool, or a ne tooth le, remove
any burrs or ridges that may exist from the drilling or cut-
ting operation.
CAUTION

Abrasive particles can damage machined surfaces and
result in premature failure.

9. Carefully pull out shop cloths from inside the transmis-
sion case. Exercise care to keep any debris captured by
the cloths from falling into the transmission case.
10. Place drain pan beneath transmission case and remove
tape from drain hole. Thoroughly ush the transmission
case with a non-volatile cleaning solution or solvent to
remove any metal shavings, dust or debris that might
remain. For best results, use a squirt bottle to direct a
stream of solvent through the transmission top cover
opening. Repeat procedure as necessary draining
excess solvent through the drain hole.
11. Using low pressure compressed air, thoroughly blow out
all solvent.
12. Using a clean lightly oiled cloth, thoroughly wipe the
inside of the transmission case. Repeat this step with a
new cloth until the cloth comes out clean.
13. Carefully inspect the transmission case for any metal
shavings or debris. Repeat steps 10 through 12 if any
debris is found.
14. Remove the masking tape to uncover remaining holes
and bores.
15. Thoroughly inspect each bore for any metal shavings,
dust or debris. Alternately direct compressed air into
each bore to be certain that it is clean and dry.

Installation

NOTE
Prelube all bearings and shafts with clean transmission or
SYN-3 lubricant prior to installation.

1. Using the appropriate service manual, proceed as fol-
lows:
a. Install the countershaft needle bearing.
b. Install the main drive gear and bearing.

NOTE
Detailed instructions on installing the main drive gear and
bearing can be found in the 2005 Touring Model Service Man-
ual (Part No. 99483-05),

Section 7.7 MAIN DRIVE GEAR/
BEARING.

c. Install shifter shaft assembly from inside the trans-
mission case. Cover splines of shaft with tape to
protect seal. Install the new shifter shaft seal.
Remove tape and install new shifter seal washer
and new retaining ring.
2. Install the transmission side door and mainshaft/counter-
shaft assembly as follows:
CAUTION

Leave the shrink wrap on the mainshaft until side door
installation is complete. Installation of the side door with
the shrink wrap removed may result in damage to the
main drive gear seal.
CAUTION

Be sure to remove the plastic cap and cable strap from
the mainshaft before side door installation. Blow away
any styrofoam bits or other packaging material that
might be clinging to gears or splines.

a. Hang

new

side door gasket on dowels in side door
ange of transmission case.
b. Start side door and mainshaft/countershaft assem-
bly into transmission case, but stop so that all gears
remain on the outboard side.

-J03483 3 of 7

c. Note that there are three shifter forks, each of which
are stamped for easy identication. Set aside the 5-
6 shifter fork, the 3-4 shifter fork and the 1-2 shifter
fork in that order.
d. Install the 5-6 shifter fork into the shift ring outboard
of the 6th gear on the mainshaft (shift ring closest to
the main drive gear).
e. Install the 3-4 shifter fork into the shift ring between
the 4th and 3rd gears on the mainshaft (shift ring
closest to the side door). Be sure the dogs on the
shift ring are engaged with mainshaft 3rd gear and
then rotate shifter fork toward the countershaft until
the slot in the fork engages the edge of the shift ring
between 1st and 2nd gears on the countershaft.
This engagement is necessary to obtain the proper
clearance for side door installation.
f. Slide side door assembly further into transmission
case stopping about one inch before mating anges
make contact.
g. Start fork shaft through hole in side door.
h. Through the transmission top cover opening, install
the 1-2 shifter fork into the shift ring between 1st and
2nd gears on the countershaft. For proper clear-
ance, be sure the dogs on the 3-4 shift ring (closest
to side door on the mainshaft) are fully engaged with
mainshaft 4th gear.
i. Slide fork shaft through holes in shifter forks and
then fully install side door. Be sure that end of fork
shaft engages plugged hole on left side of transmis-
sion case.
j. Install fork shaft set screw in transmission side door.
Tighten screw until the shaft has minimum endplay,
but still rotates freely.
k. Install

new

side door plug into side door.
l. Remove shrink wrap from the mainshaft.
3. Using the appropriate service manual, proceed as fol-
lows:
a. Install four

new

drum support block dowels in deck
of transmission case. Orient the dowels so that the
split line is aligned left to right.
b. Install

new

drum support blocks with

new

shift
drum.
c. Rotating output shaft by hand, shift through all six
gears to verify proper operation. Input shaft may
need to be rocked back and forth to get all gears to
shift.
d. Install the mainshaft oil seal, quad seal, spacer
sleeve/sprocket spacer, sprocket, and sprocket nut.

NOTE
The 2005 Touring Models Service Manual (Part Number
99483-05) includes detailed instructions on installing the
mainshaft oil seal, quad seal, spacer sleeve, sprocket and
sprocket nut in

Section 7.7, MAIN DRIVE GEAR/BEARING

.



e. Install the

new

bearing inner race onto the transmis-
sion mainshaft.
f. Install the transmission top cover with

new

gasket.
g. Install primary chaincase.
h. Install the starter and oil ller spout.

Figure 2. Install 5-6 Shifter Fork Onto Shift Ring
Figure 3. Install 3-4 Shifter Fork Onto Shift Ring
Figure 4. Install 1-2 Shifter Fork Onto Shift Ring
9450
9451
9452

-J03483 4 of 7

NOTE
If vehicle is equipped with a shotgun style exhaust system
(FLSTF/I or FXSTD/I), re-use or install new Part Number
3300 longer screws for mounting exhaust bracket to transmis-
sion side door. Torque screws to 13-16 ft-lbs (17.6 -21.7 Nm).

i. Install the starter jackshaft assembly. Install the
clutch assembly, primary chain, and compensating
sprocket components. Install the primary chaincase
cover.
j. Install drain plug and ll the primary chaincase with
the recommended lubricants.
4. Install plate with gasket over vehicle speed sensor bore
in transmission case using existing hardware.
5. Install vehicle speed sensor at top of transmission side
door using

new

O-ring.
1WARNING 1WARNING

Pull up on seat to verify that it is properly secured, front
and rear. A loose seat may shift during vehicle operation
and startle the rider, possibly causing loss of vehicle
control resulting in death or serious injury.

6. Install side cover.
For

Cable Actuated Clutch

: Follow the instructions in
the SE 6-Speed Cable Clutch Side Cover and Release
Pushrod Kit (Part Number 38752-04).
For

Hydraulic Clutch

: Follow the instructions in the
Hydraulic Cable Side Cover and Release Pushrod Kit
(Part Number 38753-04), and in the Hydraulic Clutch Kit
(Part Number 45033-03, Black or 45383-03, Chrome).

TRANSMISSION SERVICE

7. Replace the transmission lubricant after the rst 500
miles. Thereafter, refer to the Service Manual and
change the lubricant at the recommended service inter-
vals.

Figure 5. Orient Shift Drum Support Block Dowels
9455

-J03483 5 of 7

1. Mainshaft
2. Countershaft
3. Countershaft 1st Gear
4. Mainshaft 3rd Gear/
Countershaft 2nd Gear (2)
5. Mainshaft 4th Gear
6. Mainshaft 6th Gear
7. Mainshaft 1st Gear
8. Countershaft 3rd Gear/
Mainshaft 2nd Gear (2)
9. Countershaft 4th Gear
10. Shift Ring, 1-2, 3-4 (2)
11. Shift Ring, 5-6
12. Chrome Trap Door, No Ear
13. Plate Sensor
14. Shift Fork Shaft
15. Shift Fork, 1-2 Assembly
16. Shift Fork, 3-4 Assembly
17. Shift Fork, 5-6 Assembly
18. Split Cage Bearing (5)
19. Door Retaining Ring (2)
20. Trap Door Bearing (2)
21. Mainshaft/Countershaft
Locknut (2)
22. Speedo Sensor O-Ring
23. Mainshaft/Countershaft
Retaining Ring (8)
24. Mainshaft Thrust Washer (2)
25. Sprocket Spacer
26. Mainshaft Race
27. Main Case Seal
28. Case Bearing Retaining Ring
29. Qual Seal
30. Main Case Bearing
31. Mainshaft 5th Gear
32. Pillow Block, Right
33. Sleeve Detent
34. Spring Detent Arm
35. Detent Arm Screw
36. Detent Follower
37. Trap Door Gasket
38. Side Cover Gasket
39. Pushrod Thrust Washer (2)
40. Shifter Seal
41. Shifter Retaining Ring
42. Pillow Block Screw (4)
43. Shift Fork Shaft Screw
44. Countershaft Bearing
45. Clutch Release Cover
Lower Screw (4)
46. Clutch Release Cover
Upper Screw (2)
47. Lower Trap Door Screw
(FLH 4 ea.) (FXST, 2 ea.)
48. Upper Trap Door Screw (2)
49. Spline Sleeve (2)
50. Case Modication Tool
51. Shifter Seal Washer
52. Trap Door Plug
53. Sensor Plate Gasket
54. Countershaft Gear, 5th
55. Speedo Sensor Plate Screw
56. Dipstick O-Ring
57. Chrome Dipstick
58. Pillow Block Dowel (4)
59. Shift Drum Assembly
60. Left Pillow Block
61. Shift Drum Retainer
62. Shifter Shaft Assembly
Items Not Shown:
Top Cover Gasket, FLHT and FXST
Oil Fill Spout Gasket, FLHT
i06794
56
57
46
21
19
48
20
38
47
52
43
37
9
45
48
19 20
47
21
49
10
5
22
12
55
50
13 53 42
49
3
8
4 10
7
4
8
6
11
58
17
58
16
42
15
14
41 40
62
36
33
34
35
32 42
61
60
59
58 58
42
51
23
24
23
18
23 23
18
54
2 44 23
23 18 18
23
1
18 24 23
31
2827
25
30
29
26
45

Service Parts

Part No. 33102-03A Date 02/05
6 Speed Transmission Super Kit

-J03483 6 of 7

Item Quantity Part No.

1. Mainshaft 1 35058-03
2. Countershaft 1 35059-03
3. Countershaft 1st Gear 1 35080-03
4. Mainshaft 3rd Gear/Countershaft 2nd Gear 2 35083-03
5. Mainshaft 4th Gear 1 35104-03
6. Mainshaft 6th Gear 1 35131-03
7. Mainshaft 1st Gear 1 35134-03
8. Countershaft 3rd Gear/ Mainshaft 2nd Gear 2 35135-03
9. Countershaft 4th Gear 1 35136-03
10. Shift Ring, 1-2, 3-4 2 35137-03
11. Shift Ring, 5-6 1 35138-03
12. Chrome Trap Door, No Ear 1 35158-03
13. Plate Sensor 1 35153-03
14. Shift Fork Shaft 1 34088-87A
15. Shift Fork, 1-2 Assembly 1 35143-03
16. Shift Fork, 3-4 Assembly 1 35144-03
17. Shift Fork, 5-6 Assembly 1 35145-03
18. Split Cage Bearing 5 8876A
19. Door Retaining Ring 2 35087-99
20. Trap Door Bearing 2 8992A
21. Mainshaft/Countershaft Locknut 2 35078-79
22. Speedo Sensor O-Ring 1 11289A
23. Mainshaft/Countershaft
Retaining Ring 8 11067
24. Mainshaft Thrust Washer 2 6003
25. Sprocket Spacer 1 33344-94
26. Mainshaft Race 1 34091-85A
27. Main Case Seal 1 12067B
28. Case Bearing Retaining Ring 1 11161
29. Qual Seal 1 11165
30. Main Case Bearing 1 8996A
31. Mainshaft 5th Gear 1 35237-03
32. Pillow Block, Right 1 33304-00
33. Sleeve Detent 1 33375-00A
34. Spring Detent Arm 1 33374-00
35. Detent Arm Screw 1 33376-00
36. Detent Follower 1 33364-00A
37. Trap Door Gasket 1 35147-03
38. Side Cover Gasket 1 35148-03
39. Pushrod Thrust Washer 2 37313-80
40. Shifter Seal 1 12045
41. Shifter Retaining Ring 1 11150
42. Pillow Block Screw 4 3909
43. Shift Fork Shaft Screw 1 3784
44. Countershaft Bearing 1 8977
45. Clutch Release Cover
Lower Screw 4 4718A
46. Clutch Release Cover
Upper Screw 2 4717A
47. Lower Trap Door Screw
(FLH 4 ea.) (FXST, 2 ea.) 4 3249
48. Upper Trap Door Screw 2 4814A
49. Spline Sleeve 2 35140-03
50. Case Modication Tool 1 35155-03
51. Shifter Seal Washer 1 6497HW
52. Trap Door Plug 1 45830-48
53. Sensor Plate Gasket 1 35152-03

Service Parts

Part No. 33102-03A Date 08/04
6 Speed Transmission Super Kit

-J03483 7 of 7

Item Quantity Part No.

54. Countershaft Gear, 5th 1 35238-03
55. Speedo Sensor Plate Screw 1 3594
56. Dipstick O-Ring 1 11132
57. Chrome Dipstick 1 37075-87
58. Pillow Block Dowel 4 609
59. Shift Drum Assembly 1 35142-03
60. Left Pillow Block 1 33301-00A
61. Shift Drum Retainer 1 11342
62. Shifter Shaft Assembly 1 35146-03

Items Not Shown:

Oil Fill Spout Gasket, FLHT 1 62432-93B
Top Cover Gasket, FLHT and FXST 1 34904-86D

Service Parts

Part No. 33102-03A Date 08/04
6 Speed Transmission Super Kit

INSTRUCTIONS

-J03483 1 of 7

General

This kit ts 2000 and later Softail and 2001 and later Touring
model motorcycles. Requires separate purchase of Cable
Sidecover Release Kit or Hydraulic Sidecover Release kit.
See retail catalog for part numbers.
In addition to the above kits, the 2005 Touring Model Service
Manual (Part Number 99483-05) and Main Drive Gear
Remover & Installer Kit (Part Number 35316-B) must be pur-
chased. See your Harley-Davidson dealer.
For a list of items contained in this kit, see the Service Parts
illustration.
1WARNING 1WARNING

The rider's safety depends upon the correct installation
of this kit. If the procedure is not within your capabilities
or you do not have the correct tools, have your Harley-
Davidson dealer perform the installation. Improper instal-
lation of this kit could result in death or serious injury.
(00308a)

NOTE
A Service Manual for your model motorcycle is available at
any Harley-Davidson Dealer.

Removal

NOTE
Leave the transmission case in the frame unless the case
itself requires replacement. For ease of illustration, photo-
graphs show the case removed.

1. Using the appropriate service manual, proceed as fol-
lows:
a. Drain the primary chaincase and transmission lubri-
cants.
1WARNING 1WARNING

To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
battery cable before proceeding. (00048a)

b. Unthread bolt and remove battery negative cable
(black) from battery negative (-) terminal.
c. Remove seat.
d. Remove the primary chaincase cover. Remove the
clutch assembly, primary chain, and compensating
sprocket components. Remove the starter jackshaft
assembly.
e. Remove the exhaust system as necessary to gain
complete access to the transmission side door.
f. Remove the oil ller spout and starter.
g. Remove the primary chaincase.
h. Remove the clutch release cover. Remove the clutch
cable from the clutch release cover.
i. Remove the vehicle speed sensor.
j. Remove the transmission top cover.
k. Remove the drum support blocks and shift drum.
Remove the drum support block dowels from deck
of transmission case.
l. Remove the fork shaft and shifter fork assemblies.
m. Remove the bearing inner race from the transmis-
sion mainshaft.
n. Remove the transmission side door and the main-
shaft/countershaft assembly.

NOTE
The front dowel pin may be stuck in the side door after
removal. If this occurs, remove the dowel pin from the side
door and install it back into the transmission case.

o. Remove the shifter shaft assembly and shifter seal.
p. Remove the main drive gear and bearing.

GEAR STOCK 5-SPEED SE 6-SPEED

First 3.210 3.210
Second 2.209 2.209
Third 1.572 1.572
Fourth 1.226 1.226
Fifth 1.000 1.000
Sixth N/A 0.885

Figure 1. Install Drill Plate to Transmission Case
9449

-J03483
REV. 02-11-2005

Kit Number 33102-03A

6 SPEED TRANSMISSION SUPER KIT

-J03483 2 of 7

NOTE
Detailed instructions on removing the main drive gear and
bearing can be found in the 2005 Touring Model Service Man-
ual (Part No. 99483-05),

Section 7.7 MAIN DRIVE GEAR/
BEARING.

q. Remove the countershaft needle bearing.
2. Using masking tape, cover all the side door ange holes
in the transmission case with the exception of the top
three.

NOTE
While the two threaded holes at the top of the ange are used
for mounting of the drill plate, the fork shaft hole (center thru
hole) is used as the pilot for the drill bits.

3. From inside the transmission case, tape over all bores as
follows:
Vehicle speed sensor and mounting screw bores
Transmission top cover and shift drum support block
screw bores
Transmission drain hole bore
Main drive gear bearing bore
Countershaft needle bearing bore
Fork shaft bore
Shifter shaft bore
CAUTION

Be sure drill plate is properly oriented. Improper orienta-
tion will result in damage that requires replacement of
the transmission case.

4. Obtain the drill plate (Part No. 35155-03) provided in kit
and fasten to top of side door ange using old and new
vehicle speed sensor mounting screws.
5. Spread one or two clean shop cloths inside the transmis-
sion case to catch the metal shavings and debris.
6. Starting with a 3/8 inch drill bit, alternately use progres-
sively larger bits to enlarge the fork shaft hole. Finish the
drilling operation with a 3/4 inch drill bit.
7. Remove all remaining material up to the edge of the drill
plate with a die grinder or similar tool. Remove the drill
plate.
8. Using emery cloth, steel wool, or a ne tooth le, remove
any burrs or ridges that may exist from the drilling or cut-
ting operation.
CAUTION

Abrasive particles can damage machined surfaces and
result in premature failure.

9. Carefully pull out shop cloths from inside the transmis-
sion case. Exercise care to keep any debris captured by
the cloths from falling into the transmission case.
10. Place drain pan beneath transmission case and remove
tape from drain hole. Thoroughly ush the transmission
case with a non-volatile cleaning solution or solvent to
remove any metal shavings, dust or debris that might
remain. For best results, use a squirt bottle to direct a
stream of solvent through the transmission top cover
opening. Repeat procedure as necessary draining
excess solvent through the drain hole.
11. Using low pressure compressed air, thoroughly blow out
all solvent.
12. Using a clean lightly oiled cloth, thoroughly wipe the
inside of the transmission case. Repeat this step with a
new cloth until the cloth comes out clean.
13. Carefully inspect the transmission case for any metal
shavings or debris. Repeat steps 10 through 12 if any
debris is found.
14. Remove the masking tape to uncover remaining holes
and bores.
15. Thoroughly inspect each bore for any metal shavings,
dust or debris. Alternately direct compressed air into
each bore to be certain that it is clean and dry.

Installation

NOTE
Prelube all bearings and shafts with clean transmission or
SYN-3 lubricant prior to installation.

1. Using the appropriate service manual, proceed as fol-
lows:
a. Install the countershaft needle bearing.
b. Install the main drive gear and bearing.

NOTE
Detailed instructions on installing the main drive gear and
bearing can be found in the 2005 Touring Model Service Man-
ual (Part No. 99483-05),

Section 7.7 MAIN DRIVE GEAR/
BEARING.

c. Install shifter shaft assembly from inside the trans-
mission case. Cover splines of shaft with tape to
protect seal. Install the new shifter shaft seal.
Remove tape and install new shifter seal washer
and new retaining ring.
2. Install the transmission side door and mainshaft/counter-
shaft assembly as follows:
CAUTION

Leave the shrink wrap on the mainshaft until side door
installation is complete. Installation of the side door with
the shrink wrap removed may result in damage to the
main drive gear seal.
CAUTION

Be sure to remove the plastic cap and cable strap from
the mainshaft before side door installation. Blow away
any styrofoam bits or other packaging material that
might be clinging to gears or splines.

a. Hang

new

side door gasket on dowels in side door
ange of transmission case.
b. Start side door and mainshaft/countershaft assem-
bly into transmission case, but stop so that all gears
remain on the outboard side.

-J03483 3 of 7

c. Note that there are three shifter forks, each of which
are stamped for easy identication. Set aside the 5-
6 shifter fork, the 3-4 shifter fork and the 1-2 shifter
fork in that order.
d. Install the 5-6 shifter fork into the shift ring outboard
of the 6th gear on the mainshaft (shift ring closest to
the main drive gear).
e. Install the 3-4 shifter fork into the shift ring between
the 4th and 3rd gears on the mainshaft (shift ring
closest to the side door). Be sure the dogs on the
shift ring are engaged with mainshaft 3rd gear and
then rotate shifter fork toward the countershaft until
the slot in the fork engages the edge of the shift ring
between 1st and 2nd gears on the countershaft.
This engagement is necessary to obtain the proper
clearance for side door installation.
f. Slide side door assembly further into transmission
case stopping about one inch before mating anges
make contact.
g. Start fork shaft through hole in side door.
h. Through the transmission top cover opening, install
the 1-2 shifter fork into the shift ring between 1st and
2nd gears on the countershaft. For proper clear-
ance, be sure the dogs on the 3-4 shift ring (closest
to side door on the mainshaft) are fully engaged with
mainshaft 4th gear.
i. Slide fork shaft through holes in shifter forks and
then fully install side door. Be sure that end of fork
shaft engages plugged hole on left side of transmis-
sion case.
j. Install fork shaft set screw in transmission side door.
Tighten screw until the shaft has minimum endplay,
but still rotates freely.
k. Install

new

side door plug into side door.
l. Remove shrink wrap from the mainshaft.
3. Using the appropriate service manual, proceed as fol-
lows:
a. Install four new drum support block dowels in deck
of transmission case. Orient the dowels so that the
split line is aligned left to right.
b. Install new drum support blocks with new shift
drum.
c. Rotating output shaft by hand, shift through all six
gears to verify proper operation. Input shaft may
need to be rocked back and forth to get all gears to
shift.
d. Install the mainshaft oil seal, quad seal, spacer
sleeve/sprocket spacer, sprocket, and sprocket nut.
NOTE
The 2005 Touring Models Service Manual (Part Number
99483-05) includes detailed instructions on installing the
mainshaft oil seal, quad seal, spacer sleeve, sprocket and
sprocket nut in Section 7.7, MAIN DRIVE GEAR/BEARING.

e. Install the new bearing inner race onto the transmis-
sion mainshaft.
f. Install the transmission top cover with new gasket.
g. Install primary chaincase.
h. Install the starter and oil ller spout.
Figure 2. Install 5-6 Shifter Fork Onto Shift Ring
Figure 3. Install 3-4 Shifter Fork Onto Shift Ring
Figure 4. Install 1-2 Shifter Fork Onto Shift Ring
9450
9451
9452
-J03483 4 of 7
NOTE
If vehicle is equipped with a shotgun style exhaust system
(FLSTF/I or FXSTD/I), re-use or install new Part Number
3300 longer screws for mounting exhaust bracket to transmis-
sion side door. Torque screws to 13-16 ft-lbs (17.6 -21.7 Nm).
i. Install the starter jackshaft assembly. Install the
clutch assembly, primary chain, and compensating
sprocket components. Install the primary chaincase
cover.
j. Install drain plug and ll the primary chaincase with
the recommended lubricants.
4. Install plate with gasket over vehicle speed sensor bore
in transmission case using existing hardware.
5. Install vehicle speed sensor at top of transmission side
door using new O-ring.
1WARNING 1WARNING
Pull up on seat to verify that it is properly secured, front
and rear. A loose seat may shift during vehicle operation
and startle the rider, possibly causing loss of vehicle
control resulting in death or serious injury.
6. Install side cover.
For Cable Actuated Clutch: Follow the instructions in
the SE 6-Speed Cable Clutch Side Cover and Release
Pushrod Kit (Part Number 38752-04).
For Hydraulic Clutch: Follow the instructions in the
Hydraulic Cable Side Cover and Release Pushrod Kit
(Part Number 38753-04), and in the Hydraulic Clutch Kit
(Part Number 45033-03, Black or 45383-03, Chrome).
TRANSMISSION SERVICE
7. Replace the transmission lubricant after the rst 500
miles. Thereafter, refer to the Service Manual and
change the lubricant at the recommended service inter-
vals.
Figure 5. Orient Shift Drum Support Block Dowels
9455
-J03483 5 of 7

1. Mainshaft
2. Countershaft
3. Countershaft 1st Gear
4. Mainshaft 3rd Gear/
Countershaft 2nd Gear (2)
5. Mainshaft 4th Gear
6. Mainshaft 6th Gear
7. Mainshaft 1st Gear
8. Countershaft 3rd Gear/
Mainshaft 2nd Gear (2)
9. Countershaft 4th Gear
10. Shift Ring, 1-2, 3-4 (2)
11. Shift Ring, 5-6
12. Chrome Trap Door, No Ear
13. Plate Sensor
14. Shift Fork Shaft
15. Shift Fork, 1-2 Assembly
16. Shift Fork, 3-4 Assembly
17. Shift Fork, 5-6 Assembly
18. Split Cage Bearing (5)
19. Door Retaining Ring (2)
20. Trap Door Bearing (2)
21. Mainshaft/Countershaft
Locknut (2)
22. Speedo Sensor O-Ring
23. Mainshaft/Countershaft
Retaining Ring (8)
24. Mainshaft Thrust Washer (2)
25. Sprocket Spacer
26. Mainshaft Race
27. Main Case Seal
28. Case Bearing Retaining Ring
29. Qual Seal
30. Main Case Bearing
31. Mainshaft 5th Gear
32. Pillow Block, Right
33. Sleeve Detent
34. Spring Detent Arm
35. Detent Arm Screw
36. Detent Follower
37. Trap Door Gasket
38. Side Cover Gasket
39. Pushrod Thrust Washer (2)
40. Shifter Seal
41. Shifter Retaining Ring
42. Pillow Block Screw (4)
43. Shift Fork Shaft Screw
44. Countershaft Bearing
45. Clutch Release Cover
Lower Screw (4)
46. Clutch Release Cover
Upper Screw (2)
47. Lower Trap Door Screw
(FLH 4 ea.) (FXST, 2 ea.)
48. Upper Trap Door Screw (2)
49. Spline Sleeve (2)
50. Case Modication Tool
51. Shifter Seal Washer
52. Trap Door Plug
53. Sensor Plate Gasket
54. Countershaft Gear, 5th
55. Speedo Sensor Plate Screw
56. Dipstick O-Ring
57. Chrome Dipstick
58. Pillow Block Dowel (4)
59. Shift Drum Assembly
60. Left Pillow Block
61. Shift Drum Retainer
62. Shifter Shaft Assembly
Items Not Shown:
Top Cover Gasket, FLHT and FXST
Oil Fill Spout Gasket, FLHT
i06794
56
57
46
21
19
48
20
38
47
52
43
37
9
45
48
19 20
47
21
49
10
5
22
12
55
50
13 53 42
49
3
8
4 10
7
4
8
6
11
58
17
58
16
42
15
14
41 40
62
36
33
34
35
32 42
61
60
59
58 58
42
51
23
24
23
18
23 23
18
54
2 44 23
23 18 18
23
1
18 24 23
31
2827
25
30
29
26
45
Service Parts
Part No. 33102-03A Date 02/05
6 Speed Transmission Super Kit
-J03483 6 of 7

Item Quantity Part No.

1. Mainshaft 1 35058-03
2. Countershaft 1 35059-03
3. Countershaft 1st Gear 1 35080-03
4. Mainshaft 3rd Gear/Countershaft 2nd Gear 2 35083-03
5. Mainshaft 4th Gear 1 35104-03
6. Mainshaft 6th Gear 1 35131-03
7. Mainshaft 1st Gear 1 35134-03
8. Countershaft 3rd Gear/ Mainshaft 2nd Gear 2 35135-03
9. Countershaft 4th Gear 1 35136-03
10. Shift Ring, 1-2, 3-4 2 35137-03
11. Shift Ring, 5-6 1 35138-03
12. Chrome Trap Door, No Ear 1 35158-03
13. Plate Sensor 1 35153-03
14. Shift Fork Shaft 1 34088-87A
15. Shift Fork, 1-2 Assembly 1 35143-03
16. Shift Fork, 3-4 Assembly 1 35144-03
17. Shift Fork, 5-6 Assembly 1 35145-03
18. Split Cage Bearing 5 8876A
19. Door Retaining Ring 2 35087-99
20. Trap Door Bearing 2 8992A
21. Mainshaft/Countershaft Locknut 2 35078-79
22. Speedo Sensor O-Ring 1 11289A
23. Mainshaft/Countershaft
Retaining Ring 8 11067
24. Mainshaft Thrust Washer 2 6003
25. Sprocket Spacer 1 33344-94
26. Mainshaft Race 1 34091-85A
27. Main Case Seal 1 12067B
28. Case Bearing Retaining Ring 1 11161
29. Qual Seal 1 11165
30. Main Case Bearing 1 8996A
31. Mainshaft 5th Gear 1 35237-03
32. Pillow Block, Right 1 33304-00
33. Sleeve Detent 1 33375-00A
34. Spring Detent Arm 1 33374-00
35. Detent Arm Screw 1 33376-00
36. Detent Follower 1 33364-00A
37. Trap Door Gasket 1 35147-03
38. Side Cover Gasket 1 35148-03
39. Pushrod Thrust Washer 2 37313-80
40. Shifter Seal 1 12045
41. Shifter Retaining Ring 1 11150
42. Pillow Block Screw 4 3909
43. Shift Fork Shaft Screw 1 3784
44. Countershaft Bearing 1 8977
45. Clutch Release Cover
Lower Screw 4 4718A
46. Clutch Release Cover
Upper Screw 2 4717A
47. Lower Trap Door Screw
(FLH 4 ea.) (FXST, 2 ea.) 4 3249
48. Upper Trap Door Screw 2 4814A
49. Spline Sleeve 2 35140-03
50. Case Modication Tool 1 35155-03
51. Shifter Seal Washer 1 6497HW
52. Trap Door Plug 1 45830-48
53. Sensor Plate Gasket 1 35152-03
Service Parts
Part No. 33102-03A Date 08/04
6 Speed Transmission Super Kit
-J03483 7 of 7

Item Quantity Part No.

54. Countershaft Gear, 5th 1 35238-03
55. Speedo Sensor Plate Screw 1 3594
56. Dipstick O-Ring 1 11132
57. Chrome Dipstick 1 37075-87
58. Pillow Block Dowel 4 609
59. Shift Drum Assembly 1 35142-03
60. Left Pillow Block 1 33301-00A
61. Shift Drum Retainer 1 11342
62. Shifter Shaft Assembly 1 35146-03
Items Not Shown:
Oil Fill Spout Gasket, FLHT 1 62432-93B
Top Cover Gasket, FLHT and FXST 1 34904-86D
Service Parts
Part No. 33102-03A Date 08/04
6 Speed Transmission Super Kit